Operator Station Visualization Sync for Responsive Plant Control
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Solution Overview
Problem
Current control systems with a web browser-based operator station client experience time delays and inconsistencies in visualization information due to the 'server-client' communication loop, leading to usability issues when manipulating graphic structures, particularly in hierarchical diagrams like SFC structures, where graphic objects may 'hang' or become misplaced during movement.
Innovation Solution
Implementing a control system with an operator station server and client that uses checksums to ensure consistency between the graphical representation and the data model, by generating and comparing checksums for the graphic presentation and data model after each command, allowing immediate reaction to operator inputs while maintaining MVC scheme integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator station server processes commands and transmits revised visualization information through the server-client communication loop, then the data model consistency is maintained, but time delays occur and the graphical representation becomes inconsistent during manipulation
Solution Approach 1:
The system segments the command processing into two independent parts: local processing by the control unit for immediate graphical updates, and server processing for data model consistency. This segmentation allows parallel execution of both functions without mutual blocking, resolving the contradiction between speed and consistency.
Solution Approach 2:
The control unit acts as an intermediary that receives commands from the display unit, processes them locally to generate revised visualization information immediately, and simultaneously transmits commands to the operator station server. This intermediary role enables the system to bridge the gap between immediate local response and centralized server processing.
2Ease of operation
If the operator manipulates graphic objects in the web browser, then the graphical representation should update immediately, but the server-client communication loop causes delays and objects may 'hang' or become misplaced
Solution Approach 1:
The control unit performs preliminary processing of commands locally before server confirmation is received. It generates revised visualization information immediately based on the command parameters, allowing the graphical representation to update without waiting for the server-client round trip. This preliminary action eliminates the perceptible delay for the operator.
Solution Approach 2:
The system dynamically adjusts the processing path based on the command type. For commands requiring immediate visual feedback (object manipulation), the control unit processes them locally and sends updates to the display unit. For commands requiring server validation, it maintains the server-client loop. This dynamic approach optimizes responsiveness for interactive operations.
3Productivity
If the control unit processes commands locally and transmits revised visualization information directly to the display unit, then immediate graphical updates are achieved, but inconsistencies may arise between the graphical representation and the data model
Solution Approach 1:
The system implements a feedback mechanism where the control unit transmits commands to the operator station server, which processes them against the data model and returns confirmation. The control unit compares its local processing results with the server's validation, ensuring consistency. This feedback loop maintains reliability while allowing rapid local processing.
Solution Approach 2:
The patent replaces the traditional mechanical server-client request-response cycle with a parallel processing architecture. Instead of waiting for sequential server processing, the control unit independently processes commands and generates visualization updates, substituting the sequential mechanical loop with parallel computational paths that achieve both speed and consistency.
Data Source
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AI summary
A control system and a method for operating a control system (16) for a technical plant, in particular a manufacturing or process plant, comprising at least one operator station server (2) and one operator station client (4), wherein a data model (3) is implemented on the operator station server (2), and wherein the operator station client (4) comprises a display unit (6) and a control unit (8), the method comprising the steps: (I) transmitting visualization information (5) representing the data model (3) to the display unit (6) by the operator station server (2); (II) generating a graphical representation of the received visualization information (5) by the display unit (6); (III) receiving commands from an operator that are intended to effect a change in the graphical representation in the display unit (6) and forwarding these commands (7) to the control unit (8);(IV) Generating revised visualization information (9) from the received commands (7) and transmitting it to the display unit (6) to adapt the graphical presentation of the display unit (6); (V) Generating adaptation commands (10) from the received commands (7) and transmitting them to the data model (3) so that the operator station server (2) adapts the data model (3); (VI) Generating a checksum specific to the current graphical presentation by the display unit (6) after the display unit (6) has received the revised visualization information (5) from the control unit (8) and has subsequently adapted the graphical presentation accordingly; (VII) Generating a checksum specific to the current data model (3) by the operator station server (2) after the operator station server (2) has received the adaptation commands (10) from the control unit (8) and has subsequently adapted the data model (3) accordingly;(VIII) Transferring the checksum to the display unit (6); (IX) Comparing the checksums generated by the display unit and the operator station server (2) to detect any inconsistency between the graphical representation of the display unit (6) and the data model (3) on the operator station server (2).